Corrugated pallet shipping method

Abstract

A shipping method includes the steps of receiving stacks of flat die cut corrugated paperboard blanks from a corrugator or sheet plant; loading the stacks of blanks into a pallet assembly machine; folding the blanks together in the assembly machine to produce a corrugated paperboard pallet; and providing the pallets for shipping items to a receiver. The assembly machine folds the blanks using intermittent motion of the blanks through multiple folding sections in the assembly machine. The sections operate by positioning, clamping and folding the blanks using levers that are supported by rotary bearings and driven by pinned end mounted pneumatic cylinders. The assembly machine overcomes misalignment and shifting of the stacks of blanks by picking up single blanks from the top of the stacks using vacuum, and adjusting alignment of the blanks after being picked up but prior to being fed into the first folding section of the assembly machine.

Accordingly, I intend that these modifications and variations, and the equivalents thereof, be included within the spirit and scope of the invention as defined in the following claims, wherein I claim: 
     
       1. A shipping method comprising:
 receiving stacks of flat die cut corrugated material blanks from a corrugator or sheet plant; 
 loading said stacks of said blanks into a pallet assembly machine; 
 said pallet assembly machine folding said blanks together and producing a corrugated material pallet; 
 providing said corrugated material pallets for shipping items to a receiver; 
 said pallet assembly machine folding said blanks using intermittent motion of said blanks and said pallet assembly machine comprising multiple folding sections wherein said sections operate by positioning, clamping and folding said blanks; 
 said pallet assembly machine overcoming misalignment and shifting of said stacks of said blanks by picking up said blanks from the top of said stacks using vacuum and adjusting alignment of said blanks after picked up but prior to being fed into the first folding section of said pallet assembly machine. 
 
     
     
       2. A shipping method defined in  claim 1  wherein:
 said stacks of said blanks comprising between 80 and 280 blanks and said loading into said pallet assembly machine being done with a fork lift. 
 
     
     
       3. A shipping method defined in  claim 1  wherein:
 said pallet assembly machine being located at a shipper and providing corrugated material pallets to a palletizer based on a signal from said palletizer. 
 
     
     
       4. A shipping method defined in  claim 1  wherein:
 said adjusting alignment of said blanks being accomplished by said pallet assembly machine providing support for said blanks from at least two sides, releasing said vacuum and shifting said blanks laterally. 
 
     
     
       5. A shipping method defined in  claim 1  wherein:
 said folding sections having a total combined floor area of less than 500 square feet. 
 
     
     
       6. A shipping method defined in  claim 1  wherein:
 said folding of said blanks using levers that are supported by rotary bearings and driven by pinned end mounted pneumatic cylinders. 
 
     
     
       7. A shipping method defined in  claim 1  wherein:
 said pallet assembly machine folding said blanks using mechanical stops for the machine motions in conjunction with a computer providing time based open loop control to solenoid valves that actuate said folding. 
 
     
     
       8. A shipping method defined in  claim 1  wherein:
 said corrugated material pallets being constructed from two different blanks which form the pallet top and the pallet bottom, and said pallet assembly machine comprising three sections that fold said pallet top, fold said pallet bottom, and fold said pallet top and said pallet bottom together. 
 
     
     
       9. A shipping method defined in  claim 1  wherein:
 said pallet assembly machine folding said blanks to form at least one rib extending out of plane of each of said blanks, said ribs of said top and bottom blanks extending perpendicular to each other and having aligned notches facing each other, said machine pressing said top and bottom blanks together so that said notches interlock and maintain said ribs in closed position and producing a corrugated material pallet. 
 
     
     
       10. A shipping method comprising:
 receiving stacks of top and bottom flat die cut corrugated material blanks from a corrugator or sheet plant; 
 loading said stacks of said blanks into a pallet assembly machine; said pallet assembly machine folding said top and bottom blanks together and producing a corrugated material pallet; 
 providing said corrugated material pallets for shipping items to a receiver; 
 said pallet assembly machine folding said blanks using intermittent motion of said blanks and said pallet assembly machine comprising multiple folding sections to form said top and bottom blanks and assemble said folded top and bottom blanks together wherein said sections operate by positioning, clamping and folding said blanks; 
 said folding of said blanks accomplished using levers which are supported by rotary bearings and driven by pinned end mounted pneumatic cylinders; 
 said pallet assembly machine folding said blanks using mechanical stops for motions of said top and bottom blanks in conjunction with a computer providing time based open loop control to solenoid valves that actuate said folding. 
 
     
     
       11. A shipping method defined in  claim 10  wherein:
 said pallet assembly machine overcoming misalignment and shifting of said stacks of said blanks by picking up said blanks from the top of said stacks using vacuum and adjusting alignment of said blanks after being picked up but prior to being fed into a first folding section of said pallet assembly machine. 
 
     
     
       12. A shipping method defined in  claim 11  wherein:
 said adjusting alignment of said blanks being accomplished by said pallet assembly machine providing support for said blanks from at least two sides, releasing said vacuum and shifting said blanks laterally. 
 
     
     
       13. A shipping method defined in  claim 10  wherein:
 said folding sections having a total combined floor area of less than 500 square feet. 
 
     
     
       14. A shipping method defined in  claim 10  wherein:
 said stacks of said blanks being shipped to the location of said pallet assembly machine on slip sheets. 
 
     
     
       15. A shipping method as defined in  claim 10 , wherein
 said pallet assembly machine folding said blanks to form at least one rib extending out of plane of each of said blanks, said ribs of said top and bottom blanks extending perpendicular to each other and having aligned notches facing each other, said machine pressing said top and bottom blanks together so that said notches interlock and maintain said ribs in closed position and producing a corrugated material pallet. 
 
     
     
       16. A shipping method defined in  claim 10  wherein:
 said pallet assembly machine being located at a shipper and providing corrugated material pallets to a palletizer based on a signal from said palletizer. 
 
     
     
       17. A shipping method defined in  claim 10  wherein:
 said stacks of said blanks comprising between 80 and 280 blanks and said loading into said pallet assembly machine being done with a fork lift. 
 
     
     
       18. A shipping method defined in  claim 10  wherein:
 said corrugated material pallets being constructed from two different blanks which form the pallet top and the pallet bottom, and said pallet assembly machine comprising three sections that fold said pallet top, fold said pallet bottom, and fold said pallet top and said pallet bottom together.